Egg carton having spring-release opening mechanism

ABSTRACT

An egg carton is fabricated of a single sheet of resilient material such as foam plastic or the like to define a multi-celled bottom tray coupled to a correspondingly shaped tray cover by a resilient hinge. The forward portion of the bottom tray further defines a latch flap secured to the bottom tray by a resilient hinge. The latch flap defines a pair of projections which are received within a corresponding pair of apertures formed in the tray cover. A notch is formed in the tray cover which exposes a portion of the latch flap allowing the user to force the latch flap inwardly and release the cover latch. With the latch released, the resilience of the tray cover hinge causes the cover to spring open exposing the carton contents.

FIELD OF THE INVENTION

This invention relates generally to food product packaging and particularly to packaging of fragile materials. The present invention relates more specifically to packaging apparatus utilized in commercial packaging of eggs.

BACKGROUND OF THE INVENTION

Perhaps one of the most recognizable items in a modem food store is found in the ubiquitous egg carton. Such egg cartons have varied somewhat through the years both to fabrication and materials utilized. However, most modem egg cartons emerging in commerce generally comprise an elongated usually rectangularly shaped carton having a bottom tray formed to define a plurality of egg-receiving cell portions. The cell portions in the tray are usually provided in a pair of parallel rows each of which define six egg-receiving cells. The carton further includes a tray cover typically formed in a corresponding rectangular shape which is slightly larger in outer perimeter than the bottom tray. In most cartons, the tray cover is hinged to the upper rear edge of the bottom tray. The typical carton further includes a latch mechanism operative between the tray and the tray cover to maintain carton closure. In some egg cartons the bottom tray and tray cover are serrated along all surfaces at their mid points to facilitate tearing the carton in half to maintain cartons supporting a half dozen eggs. The eggs themselves are individually received within the bottom tray cells and are separated from each other by interior cell walls and spacing of the cells. The eggs within the cells are further protected by cushioning to avoid damage from external impacts against the egg supporting carton.

Despite the relatively simple structure of the modem egg carton, packaging practitioners have been faced with conflicting needs to provide maximum protection for the fragile eggs supported within the carton while simultaneously providing a sufficiently attractive package to motivate consumers to purchase the eggs from the particular provider. A further competing need in the packaging art relating to egg cartons is the ever present need to maintain the lowest production cost possible.

Thus, despite the apparent simplicity of the modem egg carton, a some what surprising amount of design effort and inventive activity has been expended toward improving the basic egg carton. For example, U.S. Pat. No. 5,494,164 issued to Ramirez sets forth an EGG CARTON which is integrally molded from a sheet of polystyrene material to provide a cover and tray wherein the tray defines a plurality of cells. Each cell defines a bottom, a plurality of exterior sidewalls, and a plurality of interior sidewalls extending upwardly from the bottom and surrounding each cell. The carton further provides a hinge connecting the tray and the cover. The sidewalls of each cell are configured such that expansion of the cell is bias toward the interior of the egg carton.

U.S. Pat. No. 5,102,034 issued to Amibili sets forth an EGG CONTAINER having upper and lower sections with the lower section defining a plurality of individual cells, each cell having gripping means therein to hold and securely retain a single commodity such as a single egg.

U.S. Pat. No. D484,796 issued to Buckley sets forth an EGG TRAY having an ornamental design.

U.S. Pat. No. 4,205,777 issued to Brown et al. sets forth BOXES OR PACKS FOR PACKAGING EGGS, FRUIT OR OTHER ARTICLES an egg box which is formed of a one piece molding of plastic sheet material includes a base portion having egg-receiving pockets and a cover portion having corresponding pockets hinged together along mutually adjacent edges such that the cover portion may be folded over the base portion to provide closure. In the closed position, the portions are fastened together at their respective edge portions opposite the hinge connection by cooperating studs and slots formed respectively in the two parts. The slots are of a keyhole shape and are positioned with respect to the cover part slot studs to initially engage the wider portions of the slots which are thereafter urged to the narrow portions of the slots to fasten the parts together.

Despite the substantial effort expended by packaging practitioners in attempting to improve the basic egg carton, a persistent problem continues to arise from the difficulty associated with opening the egg carton. In one instance, the problem arises to the tendency, if not compulsion, under which prospective consumers open the egg cartons to examine each egg before purchase. The consumer's efforts at examining the eggs within the egg carton often product in store damage of the eggs therein which in turn substantially increases the waste and costs of the food store operator. Also, in withdrawing one or more eggs from the container at home, the user frequently experiences difficultly in opening the egg carton to withdraw the desired number of eggs. This difficulty in opening conventional egg cartons arises in part for the need on the part of the consumer or user to securely hold the entire egg carton with one hand while manipulating the release of the cover latch with the other. This process has often proven to be difficult and frequently results in damaging eggs within the carton.

There arises therefore a continuing need in the art for ever more improved, cost effective and securely protective egg cartons. There arises a further unresolved need in the art for an improved egg carton having a cover latch which may be released by the user in a “one hand operation”.

SUMMARY OF THE INVENTION

Accordingly, it is a general object of the present invention to provide an improved egg carton. It is a more particular object of the present invention to provide an improved egg carton which reduces or virtually eliminates the egg brakeage from the consumer or user manipulation of the egg carton cover during opening of the carton. It is a still more further object of the present invention to provide an improved egg carton having a latch release mechanism operative between the bottom tray and the tray cover which may be manipulated by the user without the need for employing a two handed operation.

In accordance with the present invention, there is provided an egg carton comprising: a bottom tray defining a plurality of egg cells and an upper edge; a tray cover formed to generally coincide with the upper edge; a tray cover hinge pivotally coupling the tray cover to the bottom tray such that the tray cover is pivotable between a closed position and an open position, the tray cover hinge providing a resilient spring force urging the tray cover toward open position; a latch flap; a flap hinge pivotally coupling the latch flap to the upper edge, the flap hinge providing a resilient spring force urging the latch flap toward the tray cover; a releasable latch carried by the tray cover and the latch flap for securably restraining the tray cover in the closed position; and a notch formed in the tray cover exposing a portion of the latch flap allowing an inward force against the latch flap through the notch to release the latch allowing the tray cover to spring toward the open position.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:

FIG. 1 sets forth a prospective view of an improved egg carton constructed in accordance with the present invention shown in its closed configuration;

FIG. 2 sets forth a section view of the improved egg carton of FIG. 1 taken along section lines 2-2 therein in the closed configuration;

FIG. 3 sets forth a section view of the egg carton of FIG. 1 taken along section lines 2-2 in FIG. 1 showing the egg carton in its open configuration;

FIG. 4 sets forth a perspective view of an alternate embodiment of the present invention improved egg carton in its closed configuration; and

FIG. 5 sets forth a perspective view of an alternate embodiment of the present invention improved egg carton shown in FIG. 4 having the tray cover thereof in its open position.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

FIG. 1 sets forth a perspective view of an egg carton constructed in accordance with the present invention and generally referenced by numeral 10. Egg carton 10 is shown in its closed configuration in which a bottom tray 11 is coupled to a tray cover 12 to provide closure. Bottom tray 11 defines a plurality of egg cells 20, 21, 22, 23, 24 and 25 along the front portion thereof together with a corresponding rear row of egg cells such as egg cell 26 seen in FIG. 2. Thus, while not seen in FIG. 1 due to the perspective view therein, it will be understood that egg carton 10 supports a rear row of egg cells each generally aligned with a corresponding one of front egg cells 20 through 25. Bottom tray 11 further defines an upper edge 30 which is integrally formed with a flap hinge 41 along the front portion thereof and a tray cover hinge 14 along the rear portion thereof. Tray cover 12 is thus hingedly coupled to bottom tray 11 by hinge 14. Similarly, a generally planar latch flap 40 is hingedly coupled to upper edge 30 of bottom tray 11 by flap hinge 41. Latch flap 40 supports a plurality of projections 42, 43 and 44. Latch flap 40 further defines a center notch 31 which is generally aligned with an upwardly extending notch 17 formed in the frontal portion of tray cover 12. Tray cover 12 further defines a pair of apertures 15 and 16 aligned with projections 43 and 44 supported upon latch flap 40.

In the closed configuration shown in FIG. 1, tray cover 12 is pivoted downwardly about hinge 14 to generally overlie upper edge 30 of bottom tray 11. Correspondingly, latch flap 40 supporting projections 43 and 44 is captivated beneath the interior front surface of tray cover 12 and is generally urged toward tray cover 12 by the resilient structure of flap hinge 41. As a result, in the closed configuration shown in FIG. 1, projections 43 and 44 extend through apertures 15 and 16 respectively providing a latch mechanism which secures tray cover 12 in the closed position shown despite the resilient force of hinge 14 which, as is better seen in FIG. 2, is directed toward springing tray cover 12 upwardly about hinge 14 as shown by arrow 34. Projection 42 is received generally within notch 17 of tray cover 12 in the closed configuration shown and is generally accessible to the user via notch 31 formed in flap hinge 41 and notch 17 formed in tray cover 12.

Thus, in the closed configuration shown in FIG. 1, egg carton 10 provides complete enclosure and a protective environment for a plurality of eggs (not shown) received within the individual egg cells such as egg cells 20 through 25. In accordance with an important aspect of the present invention set forth and described below in greater detail, the releasable latch mechanism utilized in the present invention egg carton facilitates the release of the tray cover latch using the same hand as the consumer is employing to hold egg carton 10. As is also described below in greater detail, the user is able to simply hold egg carton 10 in one hand while extending the thumb of the supporting hand upwardly through notch 31 into notch 17 and against projection 42. The inward force exerted by the users thumb against projection 42 pivots latch flap 40 inwardly in the manner indicated in FIG. 2 with drawing projections 43 and 44 from apertures 15 and 16 and thereby releasing the latch operative upon cover 12. Once tray cover 12 is no longer restrained by the latch mechanism, the resilience of hinge 14 pivots tray cover 12 upwardly which in turn opens egg carton 10. In an alternate manipulation of the present invention egg carton, the user may hold egg carton 10 with one hand while engaging projection 42 with a digit of the other hand such as illustrated in FIG. 2. In either case, the operation of the latch release and the resilience of hinge 14 cause egg carton 10 to “spring open” when projection 42 and latch flap 40 are pivoted inwardly.

Closure of egg carton 10 is achieved by simply forcing tray cover 12 downwardly about hinge 14 toward the closed configuration shown in FIG. 1. During the closure of egg carton 10, the resilience of flap hinge 41 allows projections 43 and 44 to abut the interior of surface of tray cover 12 and thereby pivot latch flap 40 inwardly until projections 43 and 44 are again aligned with apertures 15 and 16. Once this alignment has been attained, the resilience of flap hinge 41 forces projections 43 and 44 outwardly through apertures 15 and 16 once again latching tray cover 12 in the closed configuration.

It will be apparent to those skilled in the art from the above-described operation that the present invention egg carton greatly simplifies the often vexing and potentially damaging process of opening egg cartons which has heretofore been provided by prior art devices. FIGS. 2 and 3 set forth respective section views of egg carton 10 in the open and closed positions while FIGS. 4 and 5 set forth below show alternate configurations of the present invention egg carton.

FIG. 2 sets forth a section view of egg carton 10 taken along section lines 2-2 in FIG. 1. As will be seen, the section view of FIG. 2 depicts egg carton 10 in its closed configuration. In this configuration, the latch mechanism of the present invention egg carton is operative to maintain closure of cover 12 upon bottom tray 11. FIG. 2 also shows a phantom line depiction of the latch mechanism in the release position in response to user manipulation of the latch mechanism.

More specifically, egg carton 10 includes a bottom tray 11 having a plurality of egg cells such as egg cells 23 and 26 formed therein. Bottom tray 11 further includes a spring hinge 14 and a spring flap hinge 41 both positioned along the upper edge portions of bottom tray 11. Egg carton 10 further includes a tray cover 12 pivotally secured to bottom tray 11 by hinge 14. A latch flap 40 is pivotally secured to the fontal edge of bottom tray 11 by a flap hinge 41. Latch flap 40 supports a plurality of projections such as projections 42 and 43. Cover 12 defines a notch 17 and a bottom edge 13.

In the closed configuration shown in FIG. 2, tray cover 12 is pivoted downwardly about hinge 14 such that the latch mechanism provided by projections 43 and 44 (seen in FIG. 1) engage respective apertures 15 and 16 (also seen in FIG. 1) formed in tray cover 12.

The latch mechanism maintaining tray cover 12 in its closed configuration is released by the application of an inward force upon projection 42 which overcomes the resilience of flap hinge 41 and forces latch flap 40 to pivot inwardly about hinge 41 in the direction indicated by arrow 33. As the user continues the inward force upon projection 42 in the direction indicated by arrow 32, latch flap 40 pivots inwardly a sufficient distance to withdraw projections 43 and 44 (seen in FIG. 1) from apertures 15 and 16 (also seen in FIG. 1) which releases the latch restraining tray cover 12. With the latch restraint released, the resilience of hinge 14 urges tray cover 12 upwardly in the direction indicated by arrow 34 pivoting tray cover 12 to the open configuration shown in FIG. 3.

FIG. 3 sets forth the section view of FIG. 2 taken along section lines 2-2 in FIG. 1 in which tray cover 12 has pivoted upwardly to its open configuration.

More specifically, egg carton 10 includes a bottom tray 11 having a plurality of egg cells such as egg cells 23 and 26 formed therein. Bottom tray 11 further includes a spring hinge 14 and a spring flap hinge 41 both positioned along the upper edge portions of bottom tray 11. Egg carton 10 further includes a tray cover 12 pivotally secured to bottom tray 11 by hinge 14. A latch flap 40 is pivotally secured to the fontal edge of bottom tray 11 by a flap hinge 41. Latch flap 40 supports a plurality of projections such as projections 42 and 43. Cover 12 defines a notch 17 and a bottom edge 13.

In the open configuration shown in FIG. 3, tray cover 12 has fully pivoted about hinge 14 in the direction of arrow 35 exposing the interior contents of bottom tray 11. Similarly, latch flap 40 has pivoted forwardly in the direction indicated by arrow 36 to its maximal forward position. As a result, the contents of egg carton 10 are readily exposed and withdraw or deposit of eggs from and to the egg cells within egg carton 10 is facilitated.

Egg carton 10 is closed by simply forcing tray cover 12 downwardly in the direction indicated by arrow 37 overcoming the resilient force of hinge 14. As tray cover 12 pivots downwardly in the direction indicated by arrow 37, undersurface 18 of tray cover 12 is brought into contact with projections 43 and 44 (projection 44 seen in FIG. 4). The continued downward pivotal movement of tray cover 12 in the direction indicated by arrow 37 produces a force against projections 43 and 44 overcoming the spring force of flap hinge 41 and pivoting latch flap 40 inwardly in the direction indicated by arrow 38. As tray cover 12 continues to pivot downwardly, latch flap 40 continues to be pivoted inwardly until projections 43 and 44 (seen in FIG. 1) are brought in alignment with apertures 15 and 16 (also seen in FIG. 1) at which point projections 43 and 44 extend forwardly through apertures 15 and 16 completing the latch closure. At this point, egg carton 10 has been returned to the closed configuration shown in FIG. 2.

FIG. 4 sets forth a perspective view of an alternate embodiment of the present invention egg carton having spring-release opening mechanism generally referenced by numeral 50. By way of overview, egg carton 50 is substantially identical to egg carton 10 set forth above in FIGS. 1 through 3 and is substantially identical in operation. The structural difference between egg carton 50 and egg carton 10 is found in the absence of projection 42 (seen in FIG. 1) which is shown in egg carton 10. Thus, egg carton 50 does not require the use of the projection upon its latch flap (latch flap 55). In all other respects, the structure, fabrication and operation of egg carton 50 will be understood to be identical to egg carton 10 set forth and described above. Thus, egg carton 50 illustrates the functionality and operability of the present invention egg carton without the need for a projection such as projection 42 upon the latch flap.

More specifically, egg carton 50 includes a bottom tray 51 having a tray cover 52 hingedly supported thereon by a resilient hinge 72. Bottom tray 51 is fabricated to define a plurality of egg cells such as egg cells 60, 61, 62, 63, 64, and 65. As mentioned above in descriptions accompanying egg carton 10, egg carton 50 will be understood to preferably include a rear row of egg cells substantial identical in arrangement to egg cells 60 through 65 at the rear portion of bottom tray 51. Tray cover 52 further defines a notch 54 together with a pair apertures 56 and 57. Apertures 56 and 57 are aligned with a corresponding pair of projections 70 and 71 which extend forwardly from latch flap 55 and are received within apertures 70 and 71 to provide a latch closure for egg carton 50. Latch flap 55 is supported by a resilient hinge 73 having a notch 59 formed therein. Flap hinge 73 couples latch flap 55 to bottom tray 51 along the frontal portion of edge 58.

Thus, in the closed position shown in FIG. 4, egg carton 50 securely encloses and protects a plurality of fragile eggs within the carton. In the closed position shown, the secure latch of tray cover 52 in its closed configuration is maintained by the extension of projections 70 and 71 through apertures 56 and 57 under the urging of the resilient force provided by flap hinge 73. Simply stated, flap hinge 73 urges latch flap 55 forwardly against the interior surface of tray cover 52.

FIG. 5 sets forth a perspective view of egg carton 50 in its open configuration. Comparison of FIGS. 4 and 5 reveals that tray cover 52 has been released from the latch closure shown in FIG. 4 and has been pivoted upwardly in the direction indicated by arrow 75 due to the resilient force of hinge 72. Similarly, it will be noted that the resilient force of flap hinge 73 has pivoted flap hinge 55 forwardly in the direction indicated by arrow 76.

More specifically, egg carton 50 includes a bottom tray 51 having a tray cover 52 hingedly supported thereon by a resilient hinge 72. Bottom tray 51 is fabricated to define a plurality of egg cells such as egg cells 60, 61, 62, 63, 64, and 65. As mentioned above in descriptions accompanying egg carton 10, egg carton 50 will be understood to preferably include a rear row of egg cells substantial identical in arrangement to egg cells 60 through 65 at the rear portion of bottom tray 51. Tray cover 52 further defines a notch 54 together with a pair apertures 56 and 57. Apertures 56 and 57 are aligned with a corresponding pair of projections 70 and 71 which extend forwardly from latch flap 55 and are received within apertures 70 and 71 to provide a latch closure for egg carton 50. Latch flap 55 is supported by a resilient hinge 73 having a notch 59 formed therein. Flap hinge 73 couples latch flap 55 to bottom tray 51 along the frontal portion of edge 58.

FIG. 5 also illustrates a plurality of eggs 80 through 85 received within egg cells 60 through 65 respectively. Eggs 80 through 85 may be readily withdrawn from egg carton 50 once tray cover 52 has been released and allowed to spring to the open configuration shown.

Thus, egg carton 50 may be opened from the closed configuration shown in FIG. 4 by a simple inward pressure within notch 54 of tray cover 52 against the exposed portion of latch flap 55. This inward force releases the restraint supplied by projections 56 and 57 extending through apertures 70 and 71. Once the restraining latch has been released, the resilience of hinge 72 provides an opening force the results of which is shown in FIG. 5. A reverse operation substantially identical to that described above in FIGS. 2 and 3 in the descriptions of egg carton 10 is carried forward in closing egg carton 50 as tray cover 52 is forced downwardly toward bottom tray 51 forcing latch flap 55 inwardly and overcoming the spring force of flap hinge 73. Once projections 70 and 71 are generally aligned with apertures 56 and 57, the resilience of flap hinge 53 allows latch flap 55 to pivot forwardly in the direction indicated by arrow 76 to complete the latching action.

While the foregoing described improved egg carton may be fabricated using a variety of materials which are capable of being formed and which provide sufficient resilience for the tray cover hinges and flap hinges, both the embodiments set forth herein as egg cartons 10 and 50 are preferably fabricated using a single sheet of a thin planar foam plastic material which may be readily heat stamped or formed by other processes into an integral one piece egg carton.

While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. 

1. An egg carton comprising: a bottom tray defining a plurality of egg cells and an upper edge; a tray cover formed to generally coincide with said upper edge; a tray cover hinge pivotally coupling said tray cover to said bottom tray such that said tray cover is pivotable between a closed position and an open position, said tray cover hinge providing a resilient spring force urging said tray cover toward open position; a latch flap; a flap hinge pivotally coupling said latch flap to said upper edge, said flap hinge providing a resilient spring force urging said latch flap toward said tray cover; a releasable latch carried by said tray cover and said latch flap for securably restraining said tray cover in said closed position; and a notch formed in said tray cover exposing a portion of said latch flap allowing an inward force against said latch flap through said notch to release said latch allowing said tray cover to spring toward said open position.
 2. The egg carton set forth in claim 1 wherein said releasable latch includes: at least one aperture formed in said tray cover; and at least one projection formed on said latch flap in alignment with said at least one aperture.
 3. The egg carton set forth in claim 2 wherein said at least one aperture is a pair of apertures and wherein at least one projection is a pair of projections.
 4. The egg carton set forth in claim 3 wherein said exposed portion of said latch flap includes a grip projection exposed through said notch.
 5. The egg carton set forth in claim 4 wherein said bottom tray, said tray cover, said latch flap, said tray cover hinge and said flap hinge are integrally formed.
 6. The egg carton set forth in claim 1 wherein said exposed portion of said latch flap includes a grip projection exposed through said notch.
 7. The egg carton set forth in claim 1 wherein said bottom tray, said tray cover, said latch flap, said tray cover hinge and said flap hinge are integrally formed. 